Impact Factor Value 4.

046 e-ISSN: 2456-3463

International Journal of Innovations in Engineering and Science, Vol. 3, No.7, 2018
www.ijies.net

“Mathematical Modeling and Analysis of Various

Parameters Responsible for Gray Cast Iron
Defects”
1 2
Mr. Sujit V Hirulkar , Mr. P.N. Awachat
1
M.Tech Student, 2Assistant Professor,
G.H. Raisoni Academy of Engineering & Technology, Hingna Wadi link road, Nagpur, Maharashtra, India

Abstract - A defect in castings does not just happen. fettling and machining. For example, if shrinkage porosity
Casting defects are unusually not by accidents, they is identified as gas porosity, and the pouring temperature
occur because some step in manufacturing cycle does is lowered to reduce the same, it may lead to another
not get properly controlled and somewhere something
defect, namely cold shut.
goes wrong. They are caused by wrong practice in one
or more of the basic operations involved in the casting
process as in the equipment used, or by the design of the CASTING DEFECTS
part. A defect may be the result of a single clearly
defined cause or a combination of factors, in which case Casting Defect is an unwanted irregularity that appears in
necessary preventive measures are more obscure. If not the casting during metal casting process. There are
controlled the rejection may be up to 50% also. Hence various reasons or sources which are responsible for the
close control and standardization of all aspects of
defects in the cast metal. Some of the defects produced
manufacturing techniques offers the best control against
the occurrence of defects in castings. Normally castings may be neglected or tolerated and some are not
also contain certain imperfections and discontinuity acceptable, it must be eliminated for better functioning of
which contribute to a normal quality variation. Such the parts.
imperfections are considered as defects when they affect
the appearance or the satisfactory sound functioning of Types of Defects
the casting. Defective casting offers ever-present Casting defects can be categorized into 5 types:
problems to the foundry industry. Defective casting
account higher losses to sand casting industry. Hence a a) Gas Porosity: Blowholes, open holes, pinholes
systematic study can overcome the defects.
b) Shrinkage defects: shrinkage cavity
c) Cold material defects: Cut and washes, swell, drops,
metal penetration, rat tail
INTRODUCTION
d) Pouring metal defects: Cold shut, misrun, slag
inclusion
Foundry industry suffers from poor quality and e) Metallurgical defects: Hot tears, hot spot.
productivity due to the large number of process
parameters, combined with lower penetration of
manufacturing automation and shortage of skilled
workers compared to other industries. Global buyers
demand defect-free castings and strict delivery schedule,
which foundries are finding it very difficult to meet.
Casting defects result in increased unit cost and
lower morale of shop floor personnel. The defects need
to be diagnosed correctly for appropriate remedial
measures, otherwise new defects may be introduced.
Unfortunately, this is not an easy task, since casting
process involves complex interactions among various
parameters and operations related to metal composition,
methods design, molding, melting, pouring, shake-out,
88
Impact Factor Value 4.046 e-ISSN: 2456-3463
International Journal of Innovations in Engineering and Science, Vol. 3, No.7, 2018
www.ijies.net

Types of Moulding Sand

The various types of moulding sand are
a) Green sand
b) Dry sand
c) Loam sand
d) Parting sand
e) Facing sand
f) Backing sand
g) System sand
h) Core sand

PROPERTIES OF MOULDING SAND IN

CASTING a) Mechanical Seal Housing

During casting of metals in the foundry shop we use sand

for the preparation of mould. It is the moulding sand
properties which improves the quality of the casting
metal. If a sand of suitable property is chosen, than it
greatly minimises the casting defects that may be
produced during the mould preparation and casting.

Properties of Moulding Sand

A moulding sand should possess the following 6
properties
1. Porosity
2. Flowability
3. Collapsibility
4. Adhesiveness
5. Cohesiveness or strength b) Existing Mould Layout
6. Refractoriness

OBJECTIVE
The following objectives are:

 To identify various causes of occurrence of

defects and put them together.
 To develop a mathematical model of parameters
responsible for casting defects.
 To identify corresponding remedies and put
them together.
 To develop a knowledge base related to casting
defects.

DESIGN AND MODELLING c) Modified Mould Layout

89
Impact Factor Value 4.046 e-ISSN: 2456-3463
International Journal of Innovations in Engineering and Science, Vol. 3, No.7, 2018
www.ijies.net
Pareto analysis works on 80/20 principle which
states that 80% of rejection occurs only because of 20%
Analysis defects. From the analysis of above Pareto chart, it is clear
that 49.35 % rejections are only because of two types of
defects which are Blow Holes and Sand Drop. So by
working on these defects we can increase the productivity
and reduce overall defect.

Figure below shows a 3D graph plot of clay versus Mold

hardness. It is clear from the figure that medium clay
percentage and mold hardness provides a better quality of
castings. With increase in clay percentage, the defects are
also noted to be increasing

Table1 : Major Casting Defects in Pump part in the

Foundry

Figure (25): 3-D Response Surface Plot

2-D Contour Plot of Clay versus Mold Hardness

6.0
Rejection
< 3
3– 6
5.8 6– 9
9 – 12
12 – 15
15 – 18
C-mold hardness

18 – 21
5.6
21 – 24
24 – 27
Chart (2): Pareto Analysis of Major Casting Defects in 27 – 30
30 – 33
5.4
the Foundry > 33

As seen from the rejection analysis out of 922 Hold Values

B-Moisture 4
Castings, 68.98% castings were rejected due to above 5.2

defects. It is seen that from 68.98% total rejection, 25.81

% castings are rejected only because of Blow Hole 5.0
2.0 2.5 3.0 3.5 4.0
defect which was identified during machining and 74.19
A-clay
% defects are because of Sand Drop, ColdShut, Core
Shift, Mould Break Groove damage and Scabbing.
Figure (26) : 2-D Response Surface Plot

90
Impact Factor Value 4.046 e-ISSN: 2456-3463
International Journal of Innovations in Engineering and Science, Vol. 3, No.7, 2018
www.ijies.net
experiments were conducted in a foundry producing
RESULT AND DISCUSSION pump components. The major parameters that were
Numerical optimization responsible for producing casting defects in pump
components were identified as proportions of clay,
By numerical optimization, the target or the
moisture and Mold hardness respectively. Each parameter
goal of the experiment can be set. Here the aim is to
was analyzed with three different levels. Further the
minimize the defective components in Mechanical Seal
contribution of the parameters was analyzed using
Housing castings. From Table below, it was noted that
ANOVA technique to find their effects. Interaction effects
there were 5 possible solutions for minimizing the defect
between the factors were also studied.
percentage close to zero.
F-Test of the ANOVA revealed that the parameters of
Mold proportion of clay and Mold hardness were equally
Clay Moisture Hardness Defec
significant in the casting process. These parameters were
noted to be more critical in producing quality cast
Solutions % % (Kg/cm2) t% Desirability
components.
1 2 4 5.25 0.31 0.937 The optimized parametric setting was determined by
2 2 3.96 5.26 0.32 0.936 Minitab software:
3 2 4 5.21 0.36 0.928 Clay – 2%
4 2 3.92 5.35 0.61 0.879
Moisture – 3.87 to 4 %
Mold Hardness – 5.21 to 5.45 kg/cm2 as a range of values
5 2 3.87 5.45 1.58 0.684
for the input conditions that can be easily practiced by
workmen in industries.

CONFIRMATION EXPERIMENTS
The main purpose of these confirmation experiments is REFERENCES
to validate the setting obtained from Design expert
1. B. Chokkalingam & S.S. Mohamed Nazirudeen,"Analysis
software which is likely to achieve the defect free of Casting Defect Through Defect Diagnostic Study
castings. A set of 10 confirmation experiments were Approach", Journal of Engineering Annals of Faculty of
conducted three times with the optimal settings Engineering Hunedoara, Vol. 2, pg no. 209-212, 2009
2. B.Ravi, “Casting Simulation and
producing 30 samples of pump adapter castings. On Optimization:Benefits,Bottlenacks and Best Pratices”,
inspecting the samples for defects, all the 30 castings Indian foundry journal, Spcial Issue,January 2008.
were found to be defect free. 3. B.Ravi,“Computer-aided Casting Design and Simulation”,
STTP,Nagpur,July21,2009.
Comparison of existing and experimented settings 4. ALWAN, L.C.; ROBERTS, H.V. Time Series Modeling
for Statistical Process Control. Journal of Business &
Sr. Existing Experimental
Economic Statistics, n. 6, p. 87-95, 1998.
No. Factors Range Range
5. BOX, G.E.P.; JENKINS, G.M. Time Series Analysis:
Clay
Forecasting and Control. San Francisco, Holden-Day
1 Percentage 1% 2%
(Revised Edition), 1970.
Moisture
2 Percentage 4% 3.87 - 4% 6. CHIAVERINI, V. Aços e ferros fundidos. ABM, 2005.
Mold 5.21 - 5.45 7. M. Eliade, The Forge and the Crucible, The University of
3 Hardness No measure kg/cm2 Chicago Press, 1978.
% Approved
8. J. Am. Foundrymen’s Assoc. 1 (1896).
castings 58.70% 100%
9. E. Nechtelberger, H. Puhr, J.B. von Nesselrode, A.
Nakayasu, Proceedings of the 49th International Foundry
Hence, the parametric settings may be taken as optimal Congress, CIATF, Chicago, 1982, Paper 1.
for producing large quantities of Mechanical Seal 10. Ben V. Takach, “The zero Defect Syndrome”, Foundry, A
Housing castings with minimal or no defects. In general, Journal for progressive metal casters, vol. –xi, No.-1, p.p.
11-13. January/ February 1999
the use of higher clay content and mold hardness with
11. B.S. Pendse, “Foundry men-Prepare for the future”,
moderate moisture percentage led to better castings as
Foundry, An Indian Journal for progressive metal caters,
shown in Table Vol. Xi, no.-3, p.p. 45-48,May/June, 1999
12. Dr. Sumit Roy, “Total Quality Management means of
CONCLUSION survival for Indian industry, a special focus on foundries”,
In this work, parametric optimization for controlling Foundry, An Indian journal for progressive metal caters,
casting defects in FG 200 Mechanical Seal Housing was p.p. 11-23.July / August 2003,
attempted by design and of experiments (DOE). Relevant
91